Ingot mold



F. KLEIN INGOT vMOLD April 30, 1929.

Filed Jan. 6. 1928 Patented Apr. 30, 1929.

UNITED STATES PATENT oFFicE.

FRIEDRICH KLEIN, OF BADEN, GERMANY, ASSIGNOR TO BENJAMIN HIRSH, 0F :BUF-

' FALO, NEW YORK.

INGOT MOLD.

Application led January 6, 1928. Serial No. 244,917.

My invention relates to improvements in methods of manufacturing ingots and molds therefor', the ingots having regions possessing diffe-rent characteristics or qualities, and more particularly to methods of manufacturing mgots from which commercial articles or objects having regions of different characteristics are to be constructed.

The primary object of my invention is the provision of an ingot wherein regions of metal of diderent hardness, qualities, or characteristics are provided, and in the method whereby such an ingot is cast.

Another object of my invention is the provision of ingots, blooms, slabs, or other primary forms of metal having at least-two regions of metal oiditferent hardness, qualities, or characteristics, from which shafts, plates, rails, plough-shares, and many other metallic objects may be rolled, forged, or otherwlse formed; witlnfor example, a hard region of metal located where such objects are subjected to greatest Wear.

Another object of my invention is to provide-metallic primary or rudimentary forms such as ingots, blooms, slabs, blanks and the like, with at least two regions of different hardness, qualities, or characteristics and from which, forinstance, metallic objects having portions thereof subjected to wear, are rolled, forged, or otherwise formed, with assurance that the tenacity in the shock-test made of such objects will be gneatly enhanced and that the danger of breaking of such objects becomes correspondingly less.

A still further object ofymy invention is the provision of a primary metallic form constructed of at least two different qualities of metal, the distribution of which may be according to the requirements of the rudi' mentary or the final product formed therefrom, and through the medium of which the hardness of the most used part of such objects may be easily controlled during the formation of such primary objects.

A further object of my invention is the production of various finished metallic products having regions of different qualities or characteristics, and wherein a great conservation of material' is possible, due to the greater hardness combined with greater tenacity created and to the different compositions of such objects and the co-relation of the different regions of such different compositions.

A still further object of my invention is the provision of a material in primary, rudimentary, or finished form having regions of different hardness whereby Wear and breakage of such material is reduced to the minimum, and which material is capable of being worked with tools, and is easily weldable, as for example in the form of rails.

A still further object of my invention is the provision of a novel method by means of which the above-mentioned objects are attained.

With the above and other objects in view to appear hereinafter, my invention consists in the production of metallic material, and especially steel, in primary, rudimentary, or nished form having regionsV of different hardness, qualities, or characteristics so disposed relatively that the hardest part is sub jected under use to greatest wear; and it further consists in the novel method by means of which ingots are manufactured and the primary or rudimentary forms of such material are created from such ingots.

In the drawings:

Fig. 1 is a vertical section through an ingot mold, equipped with my novel means for combining metals of different qualities or characteristics in a given region of the mold while retaining the separately characterized metals in other separated regions of said mold; said means being fusible under contact with the metals poured into the mold;

Fig. 2 is a cross section through the mold.

Fig. 3 is a detached perspective view of the metallic separator used as a combiner or partition wall within the mold.

Fig. 4 is a cross section through an ingot mold provided with a separator used toiprovide an ingot having a square core or central region of metal of given characteristics and an outer region of metal having different characteristics and being spaced from said core by a square region of metal possessing the combined cha 'acteristics ofthe metals in the two first-mentioned regions.

Fig. 5 is a cross section of an iugot mold having a metal separatortherein, whereby a substantially cylindrical core or central region of metal is provided having given characteristics and an outer region of metal having different characteristics and heilig spaced from said core by a circular region of metal possessing the combined characteristics of the metals in the two first-mentioned regions.

Fig. 6 is a View of a plate,cut or otherwise formed out of an ingot manufactured according to my invention and having a hard region at one end and a soft region at the other.

Fig. 7 is a perspective View of a rolled plate, cut or otherwise formed out of an ingot constructed according to my invention and having a hard region at the top and a soft bottoni region.

Fig. 8 is a cross section through a rolled bar or shaft. showing a soft core provided therefor and a hard exterior; the saine being cut orV otherwise formed out of an ingot nianufacturcd according to my invention.

Fig. 9 is a cross section through a tube, cut or otherwise formedout of an ingot manufactured aecordingto my invention and showing the inner circular region of its lwall formed of hard material and the outer region thereof of soft material; the hollow interior being created in any approved manner.

Fig. l0 is a cross section of a rail showing the base and web and a portion of its head formed of softer material than the tread or top of said head; this rail being a production fashioned out of a bloom or bar formed from an ingot of the kind mentioned. y

F ig. 11 is a dianietral section through a cai wheel showing the hub, web, and inner circumferential portion of the rim formed of comparatively soft material while the remaining circumferential portion of the rim and the flange thereof is formed of hard material; this car wlieelibeing rolled or otherwise fashioned to form from a bloom or blank cut from an ingot manufactured according to my invention. v

Attempts at the simultaneous pouring of two diti'ei'ent kinds of metal into an ingotmold have heretofore been made, but the procedure in the production of ingots of this kind has not been successful, so far as known, for the reason that the methods employed re suited in the different metals flowing one into the other without amalgamation. These dis advantages are overcome by the use of my improved process and means, inasmuch as the joining of the different metals is brought about in a manner to `assure full'and coniplete amalgamation, as will presently appear.

In the drawings, the numeral 12 designates an ingot mold of standard form and usable in asting ingots of one kind or grade of metal. ln this ingot l place whatl terni a separator 13 which, in`A` one of its preferred forms, isa specially-fashioned partition constructed of metallic plateor sheet: metal liaving comparatively small perforations lil., and at opposite sides of which within'the iiigot mold, pourging'chainhers 15, 16 are provided to receive molten metal of different qualities or characteristics. rllhis separator may also be referred to as a combiner or perforated partition wall, and it is preferably co-extensive with the length er height of the ingot mold,`

0r substantially so. In the form shown in igt/idear Figs. 1 to 3, it is constructed of a coiiipara tively wide perforated plate bent lengthwise -alon two Jarallel iinae'inai f'lines siaced apart somewhat less than the distance between two opposite walls of the ingot mold into which it is to be placed so as to form a perforated fiat cross section or side member 17 between these imaginary lines. The sheet metal or plate is bent upon itself from the edges of said cross section or side member to form converging sections or connector meinbers 18. Between the folds 19 thus formed and said two opposite walls of the mold, narrow spaces or slots 20 are provided. j The outer longitudinal edges of said converging sections or connector members 18 are spaced apart to form a vertical slot 21, and from these outer vertical edges, the plate or sheet material is again bent upon itselfI in opposite directions to form wings 22, separated bythe vertical slot 21 and having their outer or free edges incontact with said two opposite walls of the mold. These wings are arranged parallel to the cross section or side vmember 17. By thus bending the material forming this combiner or partition wall7 a large V-shaped space 23 is provided within the partition or combiner, and two smaller V-shaped Spaces 24 at opposite sides of said V-shaped space Q3. The V-shaped space 23 is wholly surrounded by the metal form ing the combiner or partition wall, except for the vertical slot Q1. The two smaller V- shaped spaces 24 are partly enclosed by the metal forming said combiner or partition wall and partly by thevwalls of the mold; these smaller V-shaped spaces being thus entirely surrounded by Valls except for the vertical spaces or slots 20 formed between the folds 19 of the combiner or partition and two opposite walls of the mold.

The combiner or partition wall so formed provides inherentlyyielding parts2 each of which consists of one of the converging niembers 18 and the wing 22 connected thereto, so that the inherent resiliency of the conibiner or partition wall retains the same in place within the mold, due to the fact that the outer edges of the wings 22 are forcibly retained in contact with two opposite walls of the ingot mold; thus making it absolutely unnecessary to provide interlocking means with the walls of the mold, and enabling the application of my invention to any common forni of ingo't mold. Assurance is therefore had that the pouring of the metal or metals into the mold will not displace the partition or combiner.

The particular combiner or partition wall, illustrated in Figs. 1 to 3, therefore provides two spaced walls maintained iii desired spaced relation by the converging sections or connector members 18. one of said walls being the cross section or side member 1i" and the other comprising the two wings the space Cox Cai

titl

stricted, access to the large V-shaped space.

centrally arranged within the combiner or partition Wall through the Vertical slot' 2l, while the metal of dilferent characteristics poured into the chamber 16 at the other side of the combiner or partition wall has like access to the two smaller V-shaped spaces 2t through the slots between the folds 19 and the opposite walls of the mold. The two metals of dii'erent characteristics poured into the moldszat opposite sides of the combiner or partition wall also enter these. V- shaped spaces through the perforations 14 formed in said combiner or partition walls,

and these metals combine one withthe other within 'the spaces 23 and Q4 and form into a single mass, gradually fusing the combiner or partition wall, which becomes fluid and amalgamates with the metals poured to form the ingot. 'llhe slots 2O and 2l are comparatively narrow, and therefore even at a high casting temperature, the flow of metal, although easy, will be restricted so that dependence is also placed on the passage of the metal through the perforations 14 formed in the plate, Yand assurance' is had, therefore, ot a perfect amalgamation of the two qualities ot metal ilowing into each other fromepposite sides of the combiner orpartition wall. Y

lin the separator, or more specifically, the combiner or partition wall described, a separated vregion is provided within the ingot mold which is disposed between the pouring chambers inte which the different metals are poured. This separated region has been designated by the numeral 25 and termed a eom' bining or mixing space or chamber. @penings in the form of slots or small holes, or both, are provided in this separator through which the two different metals are passed and caused to commingle'within this separated region, where they combine as a mixed material ot greater hardness or at least proride a metallic region ot any desired dili'erent charzurteristies other than either of the two separate materials poured into the mold. l By reason of the use of perforated walls to separate this region trom said pouring chambers, retardation of the flow of the two different metals toward and into each other is assuredv and a thorough commingling of the two dit'- ferent metals necessarily takes place. The perforated walls so used are fused or consumed and combine with the metal within the ingot mold. Aseparator, such as described, provides an ingot in which a region of metal of dili'erent and softer qualities may be arranged at opposite sides of a central region of hard metal.

lVhen forming a square or rectangular ingot with a central and an exterior region of given but different characteristics and an intermediate region in which the characteristics of the metal in the central and in terior regions are combined and a metallic region of ditl'erent qualities produced, a tubular separatorI 26 such as shown in Fig. 4, is placed within the ingot mold, thus dividing the interior of the ingot mold into two pouring chambers 27, 28, one surrounded by the separator' and the othersurrounding the separator. In this case the square tubular separator is arranged, centrally within the ingot mold and comprises two square tubular members or walls 29, 30 of different cross-sectional dimensions arranged one within the other and beinglongitudinallyco-extensive. These tubular members or walls are spaced apart and so held by props or otherwise, and the space between them serves as the combining or mixing space or chamber 31.

Like the separator illustrated in Figs. l and 2, the two tubular membersor walls 29, Btl'are provided with numerous small openings 3:2. The different metals are poured into the ingot mold, metal possessing given characteristics being poured into the chamber 27 surrounded by the separator, and metal possessing diiiierent clnnacteristics being poured into the chamber 28. The tubular separator so formed is placed centrally within the ingot mold and the metals poured simultaneously into and around Vthe same; thus making it unnecessary to interlock the separator with the Walls `of the mold.

The metal poured into the pouring chamber 27 arranged centrally within the separator', passes through the small openings in the inner tubular member or wall 29 and enters the combining or mixing space or chamber 31, while the metal poured into the pouring chamber 28 around the outer tubular member or wall 30 passes through the simili opcnmgs therein and also enters the combining or mii(- ing space or chamber' 31, where it meets and becomes thoroughly comminglcd with the metal passed thereinto from the pouring chamber S37. lhus a circular intermediate band or region is provided in the ingot which surrounds a central region or core and is surrounded by an outer circular region of metal, both of which latter possess ditl'crcnt characteristics and which characteristics are combined within the intermediate band or region of metal.

In Fig. 5 I have shown the mold cylindrical Examples of metallic objects having, for instance, hard and soft regions and being cut or otherwise formed out of ingots, or formed from blanks, blooms, orother primary forms cut out of orshaped-from ingots, are shown in Figs. 6 to 11.

In Fig. 6 isY shown a plate 3S cut or otherwise formed out of an ingot manufactured in accordance With my invention and having one end 39 formed of soft material, and the other end 4() of hard material.

In Fig. 7 is shown a rolled plate 41 having the top region 42 hard and the bottom region 43 soft.

In Fig. 8 is shown a portion of a-rolled bar or shaft 44 having a soft center or core 45 and a hard exterior 46.

In Fig. 9 I have shown a portion of a cylindrical tube, designated by the numeral 47, having the interior portion of its circumferential Wall formed of hard material, as at 48, and the exterior portion 49 of soft material.

In Fig. 1() a-rail 50 is shown, the upper por tion of the head 51 thereof being formed of hard materiahwhile the4 remainder of the head, the web 52 and the base or flange 53 are formed of soft material.

Iii-Fig. 11 I have shown in section a car wheel 54 having the tread portion 55 of its rim 56 formed of hard material while the remainder of the wheel 57 is formed of soft material.

While the ilhis'trations shown in Figs. 6 to 11 are examples of the use of my improved method and means as applied to various objects, theseexamples are onlya fevv of the many possibilities to which my invention may Y be applied.

It will he apparent that narrow slots, or openings of small area, preferably elongated, are provided in the fusible combiner or partition wall, or separating medium, as it may also be termed, through which limited quantities of metals of different qualities or char acteristics are passed, and that assurance is had of the thorough cominingling or conibining of these different metals by the passage thereof through these slots or openings and through small holes or perforations regularly spaced apart in the combiner or partition wall, or. separating device; also lthat this method can be used in the production of objects havingregions of different hardness,

either outside and inside, or at the to and bottom; for example, an iron object wit i copper covering, or steel objects which have soft regions adapted to be subjected to strain so as to avoid breakage, and hard regions where subjected to Wear. Under this method, armor plate may be manufactured which has a hard exteriorportion and a soft interior portion. Rails may be provided which have the upper portions of their heads hardened to guard against Wearing out, and which have the remaining portions thereof made out of softer quality of metal so as to withstand the stress and strains to which rails are subjected, Without possibility of breakin Shafts or rods mayalso be formed with a soft core or interior region and a hard layer at the outside thereof; in fact all kinds of metals or alloys may be cast together to form regions possessing different qualities or characteristics, as may be desired.

Separatore of various forms and construe- `tions may be used in my invention and these will possess the feature of being capable of use in connection with any standard ingot mold Without interlocking the same'with the walls of the latter. yIn each instance, the walls of the separator are formed of material which is fusible so as to combine with the metal ofthe ingot after surviving a period in which they retain their qualities of holding the poured metals from the metallic region created bv combining the poured metals, and

any suitable means embodied in the construction of these separators, allowing the metal to iow into one space from other spaces iii a restricted manner, assuring-a thorough combining of two or more metals of different characteristics, fall fully Within thc principle involved.

the use of my improved method, vari- 'B ous kinds of objects may be rolled, forged, or

otherwise fashioned to desired shape, with assurance that they will have unusual duration oflife, yet retain the tenacity required to assure against breakage; and, furthermore, the product produced under my improved method possesses the advantage that treatment thereof under heat does not influence the quality of the metal as opposed to hardened metals formed under present day methods.

Having thus described my invention, what I claim is 1. Aningot mold having a separator of fusible material placed therein and bent upon itself to be retained against opposite Walls'of the ingot mold by the inherent resiliency of the metal from which said` separator is formed. Y

2. An ingot mold having a separator formed of a fiat piece of perforated metal bent upon itself to form an intermediate flat side Wall, tivo oppositely-disposed oblique walls extending from opposite edges of said flat side wall and two Wings extending from said oblique walls' parallel with said fiat side Wall, the folds of said perforated metal formed at the juncture of said oblique Walls with said fiat side wall being spaced from opposite walls of said ingot mold to frrn narrow slots and the folds of said perforated metal formed at the juncture of said oblique Walls with said Wings being spaced apart to form a narrow slot, the outer or free edges of said Wings being in contact with said opposite walls of the ingot mold.

3. An ingot mold having a separator of fusible material placed therein so as to divide said mold into two pouring compartments separated one from the other by said separator, said separator being formed of thin perforated fusible material bent upon itself to provide two spaced Walls and form a mixing chamber between said Walls, said separator being also maintained Within said mold without interlocking connection with the Walls thereof.

In testimony whereof I aix signature.

FRIEDRICH KLEIN. 

